Bodine 1865 Guía del usuario

DC Motor Speed Control

07401043.D

www.bodine-electric.com

Instructions for Installation and Operation

Model 1865, for 115/230 VAC power supply,

with NEMA 4 enclosure and line ﬁlter for CE

Speciﬁcations

Product Type:.................................................................................. UPM-3318E4

Input Voltage: ................................................................................. 115 or 230 VAC +/- 10%,

Single Phase, 50/60Hz

Output Voltage: .............................................................................. Adjustable, 0 to 90 or

0 to 180 VDC

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QUICK REFERENCE

This manual contains the basic information needed to install and operate

Bodine DC Motor Speed Control model 1865. This manual does not profess to

cover all details or variations in equipment, nor to provide for every possible

contingency associated with installation, operation, or maintenance. No

warranty of ﬁtness for purpose is expressed or implied. Should further

information be desired or should particular problems arise which are not

covered sufﬁciently for the user’s purpose, the matter should be referred to

the Bodine Electric Company.

Figure 1 – Overview of installation for reference only and not be used

as a replacement for the detailed instructions within this manual.

IMPORTANT

Read this manual completely and carefully. Pay special attention to all

warnings, cautions, and safety rules. Failure to follow the instructions

could produce safety hazards that could injure personnel or damage the

control, motor, or other equipment. If you have any doubts about how to

connect the control or motor, refer to the detailed sections of this manual.

DIP

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TABLE OF CONTENTS

QUICK REFERENCE .....................................................2

PRODUCT SPECIFICATIONS .............................................4

IMPORTANT SAFETY PRECAUTIONS .....................................5

INSTALLATION ........................................................6

Step 1 – Examine Before Installation ..................................... 6

Step 2 – Choose a Suitable Location ......................................7

Step 3 – Mount the Control ..............................................7

CONNECTION .........................................................8

Step 4 – Preliminary Setup ..............................................8

Step 5 – Connect Motor ................................................10

Step 6 – Connect AC Line Cord ..........................................10

Step 7 – Close and Seal Enclosure ......................................10

Step 8 – Connect to AC Power ..........................................10

OPERATION ..........................................................12

Step 9 – Check System Before Operating ................................12

Step 10 – Operate the Control ...........................................13

Step 11 – Adjust Trim Pots (optional) .....................................14

TROUBLESHOOTING ..................................................17

WARRANTY ..........................................................19

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PRODUCT SPECIFICATIONS

ABOUT THIS PRODUCT—Bodine’s Model 1865 is designed to provide

variable speed control of standard Permanent Magnet DC motors. Adjustable

acceleration and deceleration are provided, making the drive suitable for soft

start applications. The full-featured drive is easy to install and operate. Simple

trim pot adjustments eliminate the computer-like programming required on

other drives. However, for most applications, no adjustments are necessary.

Table 1 – Electrical Ratings

Parameter Speciﬁcation

Input Volts 115 or 230 VAC +/- 10%, Single Phase, 50/60Hz

Max. Continuous Input Current 3.4 Amps RMS

Output Volts 0 to 90 VDC or 0 to 180 VDC

Max. Continuous Output Current 2.1 Amps DC

Max. Peak Output Current 5.1 Amps DC

Max. Form Factor 1.6

Maximum Motor HP 1/5 HP @ 90V

1/3 HP @ 180V

Table 2 - General Performance Speciﬁcations

Parameter Speciﬁcation Factory Setting

Speed Signal Input Voltage 0 – 5 VDC (must be isolated from

AC line) N/A (speed pot)

Minimum Speed Trim Pot

Range

0 – 50 VDC output to motor with

input speed signal set at 0 VDC 0 VDC (full CCW)

Maximum Speed Trim Pot

Range

60 – 100% of full motor speed with

input speed signal set at 5 VDC 100%

Acceleration Trim Pot Range

.2 – 10 seconds to ramp output

voltage up from 0 to 90 VDC and

.2 – 20 seconds to ramp up from 0

to 180 VDC

2 sec. (0-90V) 4 sec.

(0-180V)

Deceleration Trim Pot Range

.2 – 10 seconds to ramp output

voltage down from 90 to 0 VDC

and .2 – 20 seconds to ramp down

from 180 to 0 VDC

2 sec. (90-0V) 4 sec.

(180-0V)

Peak Current Limit Trim Pot

Range

0 to 200 – 250% of motor name-

plate rating with appropriate DIP

switch settings

200 – 250% (full CW)

Speed Regulation (Change in

motor speedfrom no load to

full load)

Less than 2% of Rated Speed with

most motors and less than 1%

with many

1 – 2%

Operating Temperature

Range 0 to +40OC N/A

www.bodine-electric.com 5

IMPORTANT SAFETY PRECAUTIONS

Model 1865 has been evaluated by Underwriters Laboratories for conformance

to UL standards 508 and 50 and CSA standard C22.2 No. 14 and bears the UL

Recognized Component mark.

The DC control is a power electronic device. For safety reasons, please read

through this operations manual in detail and observe those paragraphs with

the safety alert symbol.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

WARNING indicates a potentially hazardous

situation which, if not avoided, could result in

death or serious injury.

CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in

minor or moderate injury.

CAUTION used without the safety alert symbol

indicates a potentially hazardous situation

which, if not avoided, may result in property

damage.

WARNING

CAUTION

WARNING

• Do not touch printed circuit board (PCB) right after turning off power.

Wait until green LED on turns off.

• Do not attempt to wire circuitry while power is on.

• Do not attempt to examine components and signals on the PCB while the

inverter is operating.

• Do not attempt to disassemble or modify internal circuitry, wiring, or

components of the inverter.

• Enclosure must be properly grounded.

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This control should only be installed by a qualiﬁed person familiar with its

operation and associated hazards. The National Electrical Code (NEC),

local electrical and safety codes, and when applicable, the Occupational

Safety and Health Act (OSHA) should be observed to reduce hazards to

personnel and property.

INSTALLATION

NOTE: The control does not provide motor overload or over temperature

protection. The user is responsible for providing this protection in the

equipment where this control is used (Remarque: La détection de la surchauffe

du moteur n’est pas assurée par cette control).

Step 1. Examine before installation

Check that the model number on the control matches the model number

ordered. The control model number is printed as part of the serial number on an

adhesive label on the outside bottom surface of the control enclosure. Carefully

examine the control for shipping damage. Parts errors should be reported to

Bodine. Shipping damage claims should be made to the freight carrier.

Figure 2 – Location of the model number on the nameplate.

CAUTION

Do not connect the control to the power supply if there is any sign of

damage. Notify the carrier and your distributor immediately.

RoHS

COMPLIANT

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Step 2. Choose a Suitable Location

The installation site directly impacts the functionality and lifespan of the

control.

• Avoid areas where surrounding air temperature exceeds 40°C (direct

sunlight or near heating equipment or inside a panel without a cooling fan.

• Avoid locations where the front panel dial and switch may be bumped and

accidentally turned on/off or damaged.

• Avoid environments with corrosive gas.

• Avoid locations near radioactive matter or ﬂammable material.

• Avoid locations near equipment that generate electromagnetic interference

(soldering or power machinery).

• Avoid mounting the control to a surface that vibrates.

Step 3 – Mount the Control

Prepare the mounting surface by

drilling four holes with their centers

located as shown in Figure 3. If #10

screws are to be used for mounting,

then use a #6 (.204) clearance drill.

If #10- 32 machine screws are to be

used for mounting, then use a #20

(.161) tap drill. After the mounting

surface has been prepared,

mount the control with screws

through the four mounting brackets

(already attached to back of control

enclosure).

OFF• AUS• ARRET

8.44 REF

9.14

4.55 REF

6.16 REF.

SPEED•DREHZAHL•VITESSE

ON•EIN•MARCHE

40 50

100

TYPE UPM

ADJUSTABLE SPEED

TORQUE CONTROL

3.94 REF.

Figure 3 – Mounting Dimensions

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CONNECTION

CAUTION

• The PCB inside the control enclosure is vulnerable to static electrical

charges. Avoid contact with the PCB.

• Choose an appropriate power source with correct voltage settings for the

speciﬁcation of the control.

• Do not use a separate device between control and motor to switch motor

ON or OFF during operation.

Step 4 – Preliminary Setup

Figure 4 - Inside layout of control.

AC LINE VOLTAGE SELECTOR SWITCH – If the control is to be operated from a

230 VAC power supply, slide the selector switch from “115V” to “230V.”

AC LINE VOLTAGE JUMPER – If the control is to be operated from a two-phase

230 VAC power supply, where both lines are hot (typically in the USA), then

remove the jumper wire between the spades labeled “BYPS1” and “BYPS2.”

DIP SWITCHES FOR MOTOR MATCHING – Figure 4 shows a bank of 8 DIP

switches, factory-set with 4, 5, 6, and 7 ON. Set switches 1-7 to match the

type, voltage, armature speed (not output speed of geared motor), current,

and horsepower ratings on the Bodine motor nameplate per Table 3.

For non-Bodine motors, or Bodine motors not listed in Table 3, identify the motor

in Table 3 with the closest voltage, armature speed, current, and horsepower

ratings and use those DIP switch settings. Leave switch 8 OFF for 0-90 VDC

output or switch it ON for 0-180 VDC output (with 230 VAC input only).

DIP

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Table 3 – DIP Switch Settings

Bodine

Motor

Type

Rated

Volts

(DC)

Armature

Speed

(RPM)1

Rated

Current

(Amps)2

Motor

Power

(HP)

DIP

Switches

Typical Current

Range of TORQ.

Pot. (DC Amps)3

Typical Input

Current at Max.

TORQ Setting

(RMS Amps)

24A0 130 2500 0.22 1/50 Consult Bodine Support

24A2 130 2500 0.30 1/29 4,5,6,7 0-0.65 1.0

24A4 130 2500 0.48 1/17 3,4,6,7 0-0.8 1.3

24A4 90 2500 0.58 1/20 4 0-.98 1.3

24A4 90 | 130 2500 .56 | .81 1/23 | 1/11 4 0-0.92 1.3

24A46115 11500 1.1 1/7 3,5 0-1.5 8.2

33A3590 | 130 2500 .78 | 1.0 1/16 | 1/8 3,5 0-2.4 2.6

33A3 130 2500 0.74 1/12 4 0-0.92 1.3

33A3 130 2000 0.71 1/12 3 0-1.36 1.6

33A55130 2500 0.91 1/8 2,7 0-2.4 2.7

33A5 90 2500 1.6 1/7 2,4,5 0-3.0 3.8

33A5590 |130 2500 1.4| 1.8 1/8 | 1/4 3,4,5 0-2.2 2.5

33A5590 |130 2500 1.3 | 1.7 1/8 | 1/4 3,4,5 0-2.2 2.5

33A5 130 2000 1.4 1/6 3 0-1.38 1.8

33A7590 | 130 2500 1.8 | 2.4 1/6 | 1/3 2,4,5 0-3.0 3.8

42A35130 2500 1.0 1/8 2,5,7 0-3.0 4.9

42A45130 2000 1.3 1/6 2,5,7 0-2.7 4.3

42A5 90 2500 2.271/4 2,3,4,5 0-4.0 5.4

42A5590 | 130 2500 1.9 | 1.8 3/16 | 1/4 1,3,4 0-4.3 6.9

42A5590 | 130 2500 2.1 | 2.8 3/16 | 3/8 1,3,4 0-4.3 6.9

42A55130 2500 1.8 1/4 2,4,5 0-3.0 3.9

42A55130 2500 2.7 1/3 2,4,5 0-3.0 4.2

42A75130 2500 2.3 1/3 2,3,4,5 0-3.8 5.3

42A75130 2500 3.4 1/2 1,2,3,4,5 0-5.9 7.5

42A75130 2500 3.3 7/16 2,3,4,5 0-3.8 5.3

24A2 180 1725 0.13 1/19 4,6,7,8 0-0.2 0.30

24A4 180 2500 0.30 1/19 4,6,7,8 0-0.5 0.8

24A4 180 1725 0.18 1/32 4,6,7,8 0-0.3 0.40

33A3 180 1725 0.33 1/23 4,6,7,8 0-0.6 0.80

33A3 180 1725 0.31 1/23 4,6,7,8 0-0.6 0.90

33A5 180 1725 0.41 1/14 3,4,5,6,7,8 0-0.8 1.3

33A5 180 1725 0.62 1/11 3,5,6,7,8 0-1.1 1.5

33A5 180 2500 0.80 1/7 1,2,3,6,8 0-2.1 2.2

33A5 180 3000 0.89 1/6 1,2,3,6,8 0-1.2 1.9

33A75180 3000 1.3 1/4 2,5,8 0-2.6 3.5

33A7 180 1725 0.88 1/6 3,5,8 0-1.7 2.0

42A5 180 1725 0.85 1/6 3,5,8 0-1.3 2.1

42A5 180 1725 0.85 1/5 3,5,8 0-1.71 2.1

42A5 180 2500 1.2 1/4 2,5,8 0-2.7 8.5

42A55180 3000 1.17 1/5 2,5,8 0-2.5 4.1

42A5 180 1725 0.85 1/6 3,5,8 0-1.7 2.1

42A7 180 1725 1.0 1/5 2,5,8 0-2.0 3.2

42A75180 3000 1.5 1/4 2,3,8 0-3.3 6.9

1. Armature speeds are based on 130VDC (or 180VDC). For armature speed of a geared motor, multiply the output speed at the drive-

shaft by the gear ratio. Note that “PWM rated” motors, or motors rated at 130 VDC, will run about 69% slower with an unﬁltered

control because of the 90VDC max output voltage.

2. If the user desires to install their own armature fuse on the control output to protect the motor from continuous overloads, base

fuse ratings on the motor current rating in this column. The fuse should be sized at 1.2 times the current rating in this column.

3. Peak current available with TORQ pot in fully CW position. This current may exceed the continuous rating of the motor, in which

case it is intended for intermittent overload conditions only. It is the user’s responsibility to make sure the application does not

exceeds continuous rating of the motor or gearing.

4. Use this column for sizing a line fuse on the control input. The fuse should be sized at 1.2 times the current rating in this column.

5. These motors are capable of exceeding the continuous output rating of the control. The loading on these motors must be limited

to keep their continuous current draw at 2.1A or less.

6. The REG potentiometer must be turned fully CCW (off) for high-speed type 24A4BEPM motor.

7. The load/current of our 42A5 “SCR Rated”, 90V, 2500 rpm gearmotors may not exceed 2.1 amps (max) rating of control.

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AC LINE FUSES – Model 1865 has a 12A fuse already installed in both the “F1”

and “F2” fuse holders. A fuse is only really necessary in “F2” if a two-phase

230 VAC power supply (with two hot sides) is used.

Step 5 – Connect the Motor

A cord should be used for the motor connection in order to properly seal

the liquid tight ﬁtting. The ﬁtting will accept cord diameters between 0.17”

and 0.47” diameter. The length of the cord should be kept short for minimum

voltage drop and only copper wire with 60O C rated insulation should be used.

Loosen the nut from the liquid tight ﬁtting and insert the cord through the

ﬁtting and into the enclosure. Connect the two motor power leads to “A1” and

“A2” on the terminal block inside the control. The terminal block will accept

wire sizes from 18 to 14 gauge. The terminal block screws should be tightened

to 6 lb-in (0.678 Nm). Connect the motor frame ground to “CHASSIS GROUND”

on the terminal block. Refer to the connection diagrams for Bodine DC motors

in Figures 5 and 6. If the motor doesn’t rotate in the desired direction as

connected, switch the two motor wires. Note that these connection diagrams

apply to Bodine motors only. When the connections are done, tighten the nut

Motor

White +

—

Black

Green or

Green-Yellow Traces

Motor

Brown +

—

Light Blue

Green-Yellow Traces

Motor

White +

—

Black

Green or

Green-Yellow Traces

Motor

Brown +

—

Light Blue

Green-Yellow Traces

on the liquid tight ﬁtting. Figure 5 – Connection diagram for

Bodine 130V DC motors.

Figure 6 – Connection diagram for Bodine 180V DC motors.

Step 6 – Connect AC Line Cord

A cord should be used for the AC power connection in order to properly seal

against water through the liquid tight ﬁtting. See Step 5 for cord and wire

speciﬁcations. Connect the hot side of the line to “L1” and the neutral side to

“L2.” Connect earth ground to the terminal labeled “CHASSIS GROUND.” The

barrier terminal block screws should be tightened to 6 lb-in (0.678 Nm).

Step 7 – Close and Seal the Enclosure

Close the hinged cover and tighten the four screws, one at each corner.

Step 8 - Connect to AC Power

After all other connections are made and the control is closed, connect the

AC line cord to the AC power supply.

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